Abstract

AbstractThe effect of adherent thickness on the fatigue performance, fatigue limit, and failure mode of adhesively bonded thin aluminum single lap joint (SLJ) was experimentally and numerically investigated. High‐cycle fatigue tests were performed, and fatigue life was estimated using various fatigue criteria and finite element modeling. Based on the experimental results, increase in adherent thickness leads to increase in fatigue limit. In addition, failure location changes from adhesive to adherent by increasing the adherent thickness. It seems that in adherent failure, selecting a sheet with higher fatigue strength is required to achieve higher fatigue life. Also, based on the analysis of different fatigue criteria, Smith‐Watson‐Topper criterion could predict the joint fatigue life more accurately by considering the mean stress effect and the plastic strain. Finally, as an important result, an unsymmetrical SLJ specimen was evaluated as an industrial case study, and the empirical estimated life was consistent with the experimental results.

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